Lightweight fire resistant composite utility pole, cross arm and brace structures

Abstract

Disclosed embodiments include hollow composite utility pole, cross arm, and brace structures and methods of manufacture of the same using fire retardant materials. Poles, cross arm, and brace structures may be manufactured using a fire resistant resin impregnated, or resin wetted, filament roving that is wound onto a mandrel, pultruded or otherwise formed into a structural part. Various pole structures and manufacturing methods are described, including chemically bonded sleeve joint structures for poles of varying size.

What is claimed is: 
     
       1. A method of making a composite utility structure component, the method comprising:
 combining a primary matrix material and a fire resistant additive; 
 combining the primary matrix material with a fiber reinforcement; and 
 forming the combined primary matrix material and fiber reinforcement into a utility structure component by filament winding the combined primary matrix material and fiber reinforcement onto a forming mandrel. 
 
     
     
       2. The method of  claim 1  wherein the fire resistant additive is selected from the group consisting of:
 huntite, hydromagnesite, aluminum hydroxide, magnesium hydroxide, melamine cyanurate, melamine polyphosphate, melamine phosphate, organobromine compounds, or brominated, halogenated, organophosphorous, or metal hydroxide flame retardants. 
 
     
     
       3. The method of  claim 1  wherein the fiber reinforcement is selected from the group of fibers consisting of:
 basalt, carbon, glass, or poly-para-phenylene terephthalamide. 
 
     
     
       4. The method of  claim 1  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a plurality of segments of a utility pole wherein the plurality of segments are configured to assemble into a utility structure. 
 
     
     
       5. The method of  claim 1  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a cross arm or brace for a utility structure. 
 
     
     
       6. A method of making a composite utility structure component, the method comprising:
 combining a primary matrix material and a fire resistant additive; 
 combining the primary matrix material with a fiber reinforcement; and forming the combined primary matrix material and fiber reinforcement into a utility structure component by ring winding the combined primary matrix material and fiber reinforcement onto a forming mandrel. 
 
     
     
       7. The method of  claim 6  wherein the fire resistant additive is selected from the group consisting of:
 huntite, hydromagnesite, aluminum hydroxide, magnesium hydroxide, melamine cyanurate, melamine polyphosphate, melamine phosphate, organobromine compounds, or brominated, halogenated, organophosphorous, or metal hydroxide flame retardants. 
 
     
     
       8. The method of  claim 6  wherein the fiber reinforcement is selected from the group of fibers consisting of:
 basalt, carbon, glass, or poly-para-phenylene terephthalamide. 
 
     
     
       9. The method of  claim 6  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a plurality of segments of a utility pole wherein the plurality of segments are configured to assemble into a utility structure. 
 
     
     
       10. The method of  claim 6  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a cross arm or brace for a utility structure. 
 
     
     
       11. A method of making a composite utility structure component, the method comprising:
 combining a primary matrix material and a fire resistant additive; 
 combining the primary matrix material with a fiber reinforcement; and forming the combined primary matrix material and fiber reinforcement into a utility structure component by pultruding the combined primary matrix material and fiber reinforcement. 
 
     
     
       12. The method of  claim 11  wherein the fire resistant additive is selected from the group consisting of:
 huntite, hydromagnesite, aluminum hydroxide, magnesium hydroxide, melamine cyanurate, melamine polyphosphate, melamine phosphate, organobromine compounds, or brominated, halogenated, organophosphorous, or metal hydroxide flame retardants. 
 
     
     
       13. The method of  claim 11  wherein the fiber reinforcement is selected from the group of fibers consisting of:
 basalt, carbon, glass, or poly-para-phenylene terephthalamide. 
 
     
     
       14. The method of  claim 11  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a plurality of segments of a utility pole wherein the plurality of segments are configured to assemble into a utility structure. 
 
     
     
       15. The method of  claim 11  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a cross arm or brace for a utility structure. 
 
     
     
       16. A method of making a composite utility structure component, the method comprising:
 combining a primary matrix material and a fire resistant additive; 
 combining the primary matrix material with a fiber reinforcement; and forming the combined primary matrix material and fiber reinforcement into a utility structure component by table wrapping the combined primary matrix material and fiber reinforcement. 
 
     
     
       17. The method of  claim 16  wherein the fire resistant additive is selected from the group consisting of:
 huntite, hydromagnesite, aluminum hydroxide, magnesium hydroxide, melamine cyanurate, melamine polyphosphate, melamine phosphate, organobromine compounds, or brominated, halogenated, organophosphorous, or metal hydroxide flame retardants. 
 
     
     
       18. The method of  claim 16  wherein the fiber reinforcement is selected from the group of fibers consisting of:
 basalt, carbon, glass, or poly-para-phenylene terephthalamide. 
 
     
     
       19. The method of  claim 16  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a plurality of segments of a utility pole wherein the plurality of segments are configured to assemble into a utility structure. 
 
     
     
       20. The method of  claim 16  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a cross arm or brace for a utility structure. 
 
     
     
       21. A method of making a composite utility structure component, the method comprising:
 combining a primary matrix material and a fire resistant additive; 
 combining the primary matrix material with a fiber reinforcement; and forming the combined primary matrix material and fiber reinforcement into a utility structure component by fiber placing the combined primary matrix material and fiber reinforcement. 
 
     
     
       22. The method of  claim 21  wherein the fire resistant additive is selected from the group consisting of:
 huntite, hydromagnesite, aluminum hydroxide, magnesium hydroxide, melamine cyanurate, melamine polyphosphate, melamine phosphate, organobromine compounds, or brominated, halogenated, organophosphorous, or metal hydroxide flame retardants. 
 
     
     
       23. The method of  claim 21  wherein the fiber reinforcement is selected from the group of fibers consisting of:
 basalt, carbon, glass, or poly-para-phenylene terephthalamide. 
 
     
     
       24. The method of  claim 21  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a plurality of segments of a utility pole wherein the plurality of segments are configured to assemble into a utility structure. 
 
     
     
       25. The method of  claim 21  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a cross arm or brace for a utility structure. 
 
     
     
       26. A method of making a composite utility structure component, the method comprising:
 combining a primary matrix material and a fire resistant additive; 
 combining the primary matrix material with a fiber reinforcement; and forming the combined primary matrix material and fiber reinforcement into a utility structure component by tape placing the combined primary matrix material and fiber reinforcement. 
 
     
     
       27. The method of  claim 26  wherein the fire resistant additive is selected from the group consisting of:
 huntite, hydromagnesite, aluminum hydroxide, magnesium hydroxide, melamine cyanurate, melamine polyphosphate, melamine phosphate, organobromine compounds, or brominated, halogenated, organophosphorous, or metal hydroxide flame retardants. 
 
     
     
       28. The method of  claim 26  wherein the fiber reinforcement is selected from the group of fibers consisting of:
 basalt, carbon, glass, or poly-para-phenylene terephthalamide. 
 
     
     
       29. The method of  claim 26  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a plurality of segments of a utility pole wherein the plurality of segments are configured to assemble into a utility structure. 
 
     
     
       30. The method of  claim 26  wherein the step of forming the combined primary matrix material and fiber reinforcement into a utility structure component further comprises:
 forming a cross arm or brace for a utility structure.